Method of installing a fastener to secure metal panel to wood element

ABSTRACT

Fasteners are provided that include a head and having a head, a tip end having a tip, a first body portion having first threads having a pitch angle, and a second body portion having second threads, the second threads having a different pitch than the first threads. The first body portion is adjacent to the tip end of the fastener and extends a first distance along a length of the fastener towards the head end. The second body portion is adjacent to the first body portion, and extends the head end of the fastener and extending a second distance along the length of the fastener towards the head end.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.13/036,465, filed on Feb. 28, 2011 now abandoned, currently, whichclaims the benefit of U.S. Provisional Application Ser. No. 61/309,665,filed Mar. 2, 2010, which has expired.

FIELD OF THE INVENTION

The present technology relates to fasteners and methods of installingfasteners, and particularly fasteners that can be used to secure metalpanels to wood building structures.

BACKGROUND

In the construction industry, post frame metal building materials areattached to the wooden frame structure with various types of woodfasteners. However, current wood fastener thread designs have a tendencyto back-out over time, thus weakening the connection and the building'sstructural integrity. Additionally, known fasteners can have a tendencyto break during installation due to high drive torques in certain highdensity materials, as well as having a tendency to strip-out in certainlow density materials.

SUMMARY OF THE INVENTION

The present technology relates to fasteners and methods of installingfasteners in order to secure metal panels to wood building structures.

In one aspect, a fastener is provided that includes a head end having ahead, a tip end having a tip, a first body portion, and a second bodyportion. The first body portion is adjacent to the tip end of thefastener and extends a first distance along a length of the fastenertowards the head end. The first body portion includes first threadshaving a pitch angle α of less than about 60°. The second body portionis adjacent to first body portion and extends a second distance alongthe length of the fastener towards the head end. The second body portionincludes second threads having a different pitch than the threads of thefirst body portion. The second threads of the second body portion can beleft-hand threads or right-hand threads.

In a second aspect, a fastener is provided that includes a head andhaving a head, a tip end having a tip, a first body portion, and asecond body portion. The first body portion is adjacent to the tip endof the fastener and extends a first distance along a length of thefastener towards the head end. The first body portion includes firstthreads having a first pitch, and a pitch angle α from about 20° toabout 40°. The second body portion is adjacent to first body portion andextends a second distance along the length of the fastener towards thehead end. The second body portion includes second threads having asecond pitch, the second pitch being different than the first pitch ofthe first threads on the first body portion. The threads of the secondbody portion can be left-hand threads or right-hand threads having apitch angle α from about 20° to about 40°.

In a third aspect, a method of installing a fastener to secure a metalpanel to a wood structural element is provided that includes the stepsof creating a bur of metal as a tip of the fastener penetrates the metalpanel; causing an area of the metal panel immediately surrounding thefastener to pull away from the wood structural element as first threadson a first body portion of the fastener pass through the metal panel;contacting the bur of metal with threads on a second body portion of thefastener; removing the bur of metal as the threads on the second bodyportion pass through the metal panel; pushing the area of the metalpanel towards the wood structural element; and contacting the woodstructural element with the area of the metal panel prior to the area ofthe metal panel being contacted with the head of the fastener.

BRIEF DESCRIPTION OF THE DRAWINGS

Specific examples have been chosen for purposes of illustration anddescription, and are shown in the accompanying drawings, forming a partof the specification.

FIG. 1 is a side elevational view of one example of a fastener of thepresent technology.

FIG. 1A is a detail view of the area A of FIG. 1.

FIG. 2 is a perspective view of a second example of a fastener of thepresent technology, having a sealing washer assembled therewith.

FIG. 3 is a side elevational view of the fastener of FIG. 2, having asealing washer assembled therewith.

FIG. 4 is a side elevational view of a third example of a fastener ofthe present technology.

FIG. 5 is a flow chart illustrating one example of a method of using afastner of the present technology.

DETAILED DESCRIPTION

Fasteners of the present technology can be used in any suitableapplication, but are most particularly suited to constructionapplications in which metal building materials are secured to wood framestructures.

FIGS. 1-4 illustrate examples of a fastener 100 of the presenttechnology. The same reference numbers have been used for aspects thatare the same in each of the illustrated examples. The fastener 100 canbe made of any suitable material, including for example carbon steel.Additionally, the fastener 100 can have a coating, such as a coating toimprove the weather resistance properties of the fastener 100. Afastener 100 can have any suitable length, including but not limited to1 inch, 1.5 inches, 2 inches, 2.5 inches, or 3 inches.

As illustrated in FIGS. 1-4, the fastener 100 has a body 102 thatincludes a tip end 104 and a head end 106. The fastener 100 has a point108 at the tip end 104 of the body, and a head 110 at the head end 106of the body. The fastener 100 also has a first body portion 112 that isadjacent to the tip end 104 and includes first threads 114, and a secondbody portion 116 that is adjacent to the head end 106 and includessecond threads 118. The head of the fastener 100 can be any suitablestyle. The tip end 104 of the fastener 100 can include one or morepartially formed threads 126. The point 108 of the fastener 100 caninclude a sharp, self-tapping point. In the illustrated example, thefastener 100 has a type-17 point, which can allow for desiredpenetration in lapped metal conditions. As illustrated in FIGS. 2 and 3,a sealing washer 132 can be included with, or assembled to a fastener100. The sealing washer 132 can be any suitable material, such asrubber, and may be placed on the fastener 100 adjacent to and abuttingthe head 106.

The first body portion of the fastener 100 is adjacent to the tip end104 of the fastener 100 and extends a first distance D₁ along the lengthof the fastener 100 towards the head end 106. The first body portion 112includes first threads 114, which as illustrated can be right-handthreads. The first threads 114 can be single or multi-lead threads. Thefirst threads 114 can have any suitable diameter and number of threadsper inch of length along the body of the fastener. For example, thefirst threads 114 of the illustrated embodiment are 10-14 threads,having a #10 diameter, which is a major diameter of about 0.19 inchesplus or minus normal ANSI tolerances, and about 14 threads per inch. Asillustrated in the detail call-out of FIG. 1A, the first threads 114have a first pitch A, which is the linear distance between the crest ofone thread and the crest of the next thread. First threads 114 also havea pitch angle α that is less than standard threads having a 60° pitchangle. For example, the first threads 114 of the fastener 100 can have apitch angle α that is from 20° to about 40°.

The pitch angle α of the first threads 114 can have a 0° to 10°/20° to30° geometric configuration. In such an example, each thread has a firstinternal angle β on the tip side 120 of the thread, which faces towardsthe tip 108 of the fastener 100, and a second internal angle γ on thehead side 122 of the thread, which faces the head end 110 of thefastener 100. For example, the tip side 120 and the head side 122 ofeach thread slope towards each other from the base of the thread andmeet at a point 124 that is a certain height from the body 102 of thefastener 100. When a vertical reference line B is drawn to the body ofthe fastener from the point 124, the tip side 120 of the thread slopesaway from the vertical reference line at the first internal angle β,which can be from about 20° to about 30°. In such an example, the headside 122 of the thread slopes away from the vertical reference line atthe second internal angle γ, which can be from about 0° to about 10°.For example, the thread pitch angle α can be about 30°, with the firstinternal angle β of the tip side 120 being about 20°, and the secondinternal angle γ of the head side 122 being about 10°. In at least someexamples, the geometric configuration of the threads can improve thefastener's resistance to backing out over time after installation.

In some examples, one or more of the first fully formed first threads114 on the first body portion 112, which are the threads closest to thetip end 104 of the fastener, can include serrations 128. In at least oneexample, at least one of the first three fully formed first threads 114on the first body portion 112, which are the threads closest to the tipend 104 of the fastener, can include serrations 128. For example, one,two, or all three of the first fully formed first threads 114 caninclude serrations 128. In the examples illustrated in FIGS. 1 and 2,the first two fully formed threads include serrations 128. In theexample illustrated in FIG. 2, the serrations 128 can be teeth 130. Suchteeth can be rectangular, as illustrated in FIG. 2, or can have anyother suitable shape, such as being triangular. In at least someexamples, serrations 128 can reduce the drive torque needed to installthe faster 100, and facilitate installation of the fastener 100 throughknots and hardwood. Additionally, it is common that when a fastenerpierces metal siding, a bur of metal can be created, which is sometimescalled a pig-tail. The inclusion of serrations 128 can result in the burbeing removed then the serrated threads contact the bur as the fastener100 is being installed.

The second body portion 116 of the fastener 100 is adjacent to the firstbody portion 112 of the fastener 100 and extends a second distance D₂along the length of the fastener 100 towards the head end 106. Inpreferred examples, the length of the second body portion can be lessthan the length of the first body portion. For example, with referenceFIG. 1, the second distance D₂ of the second body portion 116 can beless than the first distance D₁ of the first body portion. In someexamples, such as when the total length of the fastener 100 is about 3inches or less, the length of the second body portion, which is equal tothe second distance D₂ of the second body portion, can be less than orequal to about one quarter of an inch (0.6 cm).

The second body portion 116 includes second threads 118 having a secondpitch B, the second pitch B being different than the first pitch A ofthe first threads 114. The second threads 118 of the second body portioncan be left-hand threads or right-hand threads. The second threads 118can be single or multi-lead threads. The second threads 118 can have anysuitable diameter and number of threads per inch of length along thebody of the fastener. The second body portion 116 of the fastener 100can include any number of second threads 118, including, for example,from about 1 thread to about 5 threads, or preferably from about 2threads to about 4 threads. The second threads 118 can be any suitablediameter, including for example having the same diameter as the firstthreads 114, or being oversized, meaning that the second threads 118 canhave a larger diameter than the first threads 114.

As illustrated in FIGS. 1 and 2, the second threads 118 are left-handthreads 134, and can be 10-12 threads, having a #10 diameter, which is amajor diameter of about 0.19 inches plus or minus normal ANSItolerances, and about 12 threads per inch.

As illustrated in FIG. 4, the second threads 118 are right-hand threads136, and the pitch B of the second threads 118 is less than the pitch Aof the first threads 114. In other examples, the pitch B of the secondthreads 118 could be greater than the pitch A of the first threads.

In at least some examples when a fastener is being installed throughmetal siding, the second threads 118 can result, in the bur beingremoved that is commonly created when the fastener pierces the metalsiding. Additionally, the second threads 118 can invert the edge of themetal around the insertion hole of the fastener 100, which can create asmooth surface and may prevent the metal siding from cutting anddamaging the rubber sealing washer 132. Further, while first threads 114tend to back-out over time due to expansion and contraction of thebuilding materials and the fastener when subjected to varying weatherconditions, the second threads 118 can tend to apply force in oppositedirection, resisting back-out.

In at least one application, fasteners of the present technology can beused to secure metal panels to wood building structures. One method ofinstalling a fastener 100 of the present technology can include steps ofinserting the fastener through a metal panel and into a wood structuralelement. A sealing washer 132 can be assembled to the fastener 100 priorto inserting the fastener 100 through the metal panel and into the woodstructural element. As with conventional fasteners, the step ofinserting the fastener 100 can include the fastener 100 creating a bur,or pigtail, of metal that is attached to the metal panel as the tip 108of the fastener penetrates the metal panel. Additionally, as also tendsto be observed with conventional fasteners, the step of inserting thefastener 100 can include the first threads 114 of the fastener causingan area of the metal panel immediately surrounding the fastener 100 topull away from the wood structural element, as the first threads 114 ofthe first body portion 102 of the fastener 100 pass through the metalpanel. In methods of installing conventional fasteners, creating a burof metal and causing the area of the metal panel immediately surroundingthe fastener to pull away from the wood structural element can each tendto cause damage to the sealing washer.

However, in methods of installing fasteners of the present technology,such damage to the washer may be reduced or prevented. For example, thestep of inserting a fastener 100 can also include the fastener 100removing the bur of metal as it passes through the metal panel. In someexamples, removing the bur of metal can include contacting the bur ofmetal with the second threads 118 on the second body portion of thefastener, and one or more of the second threads detaching the bur ofmetal as the second threads 118 pass through the metal panel. In onesuch example, the first threads 114 can be double lead threads, and thesecond threads 118 can be single lead threads, which may cause thesecond threads 118 to be pulled through the metal faster and thus detachthe bur. Alternatively, where the fastener includes one or more firstthreads 114 having serrations 128, removing the bur of metal can includecontacting the bur of metal with the serrations 128 on the one or morefirst threads 114, and one or more of the serrations 128 detaching thebur of metal as the one or more first threads 114 having serrations 128pass through the metal panel.

Additionally, in practice, the metal panel can stop pulling away fromthe wood structural element at the junction of the first and secondthreads. Once the second threads 118 make contact with the metal panel,the second threads 118 can push the metal panel toward the woodstructural element prior to the fastener being fully inserted, at whichpoint the area of the metal panel would be in contact with the head 110of the fastener 100, or with the sealing washer 132 that can be adjacentto and abutting the head 110 of the fastener 100. Accordingly, the stepof inserting a fastener 100 can also include pushing the area of themetal panel, which had been caused to pull away from the wood structuralelement, towards the wood structural element, and contacting the woodstructural element with the area of the metal panel prior to the area ofthe metal panel being contacted with the head of the fastener or thesealing washer adjacent to the head of the fastener. This may enable thefastener installer to know that the metal panel has made contact withthe wood structural element prior to the fastener being completelyinstalled. In such instances, the fastener installer can then apply anappropriate final seating torque to the fastener, thus properlycompressing the sealing washer; and preventing the fastener and sealingwasher from being over-torqued, which may damage the sealing washer andresult in leaks.

From the foregoing, it will be appreciated that although specificexamples have been described herein for purposes of illustration,various modifications may be made without deviating from the spirit orscope of this disclosure. It is therefore intended that the foregoingdetailed description be regarded as illustrative rather than limiting,and that it be understood that it is the following claims, including allequivalents, that are intended to particularly point out and distinctlyclaim the claimed subject matter.

What is claimed is:
 1. A method of installing a fastener to secure ametal panel to a wood structural element is provided that comprises thesteps of: creating a bur of metal with a tip of the fastener as the tipof the fastener penetrates the metal panel; causing an area of the metalpanel immediately surrounding the fastener to pull away from the woodstructural element with first threads on a first body portion of thefastener as the first threads pass through the metal panel, the firstthreads having a first pitch; removing the bur of metal as the fastenerpasses through the metal panel; pushing the area of the metal paneltowards the wood structural element with second threads on a second bodyportion of the fastener as the second threads pass through the metalpanel, the second threads having a second pitch that is different fromthe first pitch of the first threads; and contacting the wood structuralelement with the area of the metal panel prior to the area of the metalpanel being contacted with a head of the fastener or a sealing washeradjacent to the head of the fastener.
 2. The method of claim 1, whereinthe step of removing the bur of metal comprises: contacting the bur ofmetal with the second threads on the second body portion of thefastener; and detaching the bur of metal with the second threads as thesecond threads pass through the metal panel.
 3. The method of claim 1,wherein at least one of the first three fully formed first threads onthe first body portion includes serrations and the step of removing thebur of metal comprises: contacting the bur of metal with the at leastone fully formed first threads having serrations; and detaching the burof metal as the at least one fully formed first threads havingserrations pass through the metal panel.
 4. The method of claim 1,wherein the first threads are double lead threads and the second threadsare single lead threads.
 5. The method of claim 1, wherein the firstthreads have a pitch angle α that is less than about 60°, and the methodfurther includes the geometric configuration of the first threadsperforming a step of resisting back out over time.
 6. The method ofclaim 5, wherein the first threads have a pitch angle α that is fromabout 20° to about 40°.
 7. The method of claim 1, the pitch angle of thefirst threads comprising: a first internal angle β that is from about20° to about 30°; and a second internal angle γ that is from about 0° toabout 10°; wherein the method further includes the geometricconfiguration of the first threads performing a step of resisting backout over time.
 8. The method of claim 1, wherein a second distance ofthe second body portion is less than a first distance of the first bodyportion.
 9. The method of claim 1, wherein the second threads areleft-hand threads.
 10. The method of claim 1, wherein the second threadsare right-hand threads.
 11. A method of installing a fastener to securea metal panel to a wood structural element is provided that comprisesthe steps of: creating a bur of metal with a tip of the fastener as thetip of the fastener penetrates the metal panel; causing an area of themetal panel immediately surrounding the fastener to pull away from thewood structural element with first threads on a first body portion ofthe fastener as the first threads pass through the metal panel, thefirst threads being right hand threads having a first pitch, with apitch angle α that is from about 20° to about 40°; removing the bur ofmetal as the fastener passes through the metal panel; pushing the areaof the metal panel towards the wood structural element with secondthreads on a second body portion of the fastener as the second threadspass through the metal panel, the second threads having a second pitchthat is different from the first pitch of the first threads; contactingthe wood structural element with the area of the metal panel prior tothe area of the metal panel being contacted with a head of the fasteneror a sealing washer adjacent to the head of the fastener.
 12. The methodof claim 11, wherein the step of removing the bur of metal comprises:contacting the bur of metal with the second threads on the second bodyportion of the fastener; and detaching the bur of metal as the secondthreads pass through the metal panel.
 13. The method of claim 11,wherein at least one of the first three fully formed first threads onthe first body portion includes serrations and the step of removing thebur of metal comprises: contacting the bur of metal with the at leastone fully formed first threads having serrations; and detaching the burof metal as the at least one fully formed first threads havingserrations pass through the metal panel.
 14. The method of claim 11, thepitch angle of the first threads comprising: a first internal angle βthat is from about 20° to about 30°; and a second internal angle γ thatis from about 0° to about 10°; wherein the method further includes thegeometric configuration of the first threads performing a step ofresisting back out over time.